Casing for a gas-liquid contact unit



J. M. LIEBMANN CASING FOR A GAS-LIQUID CONTACT UNIT July 6, 1965 2Sheets-Sheet 1 Filed Dec. 2'7, 1960 INVENTOR. JOHN M. LIEB MANN ANDRUS8a STARKE Aifoa'neys y 6, 1965 J. M. LIEBMANN 3,193,259

CASING FOR A GAS-LIQUID CONTACT UNIT Filed Dec. 27, 1960 2 Sheets-Sheet2 INVENTOR. JOHN M. UEBMANN d BY ANDRUS 8: STARKE Attorneys UnitedStates Pate 3,193,2ss CASING FUR A GA-HQUD CUNTAUE UNKT Eohn M.Liebmanu, Madison, Wis, assignor to Research Products Corporation,Madison, Wis, a corporation of Wisconsin Filed Dec. 27, 196i), Ser. No.78,353 Claims. (6!. 251-24) This invention relates to a casing for agas-liquid contact unit.

It is often desirable to humidity dry air normally occur-ring inbuildings in wintertime. This may be accomplished by a free-standinghumidifier or one which is attached to a window or to the plenum chamberof a hot air furnace, and wherein air is circulated through thehumidifier and brought into contact with a source of moisture.

The humidifier may include, as the air moistening agent, a contact unitcomprising a plurality of superposed expanded sheets of water absorbentcharacter which are continuously wetted from a distributor disposedthereabove. Such a humidifier is disclosed in US Patent No. 2,637,- 540,assigned to the same assignee as the present invention.

According to that patent, the contact unit is disposed in a casingwherein the air passes through the housing in a single direction, andpicks up moisture from a plurality of thin fiat webs having their broadsurfaces disposed at an angle to the plane of the superposed sheetsforming the unit. A motor fan unit within the casing draws the airthrough an opening in one Wall of the casing and, after humidifying it,forces the humidified air out through an opening in an opposite wall.

The present invention provides substantial improvements over that shownin Patent No. 2,637,540. Th entire casing is preferably moldedfrom asuitable plastic material which provides smooth rounded surfacesresistant to the formation or adherence of mineral or scale depositsfrom the Water. Access to the interior of the assembled humidifier isfacilitated by providing a plurality of separable parts which aresecured together along a generally horizontal parting line by suitableattaching means.

The housing of the invention is particularly suited for mounting on thewall of an air duct or a furnace plenum chamber, since it provides forreturn of the moistened air directly back into the duct or chamber. Forthis purpose, the intake and discharge openings are disposed in the samewall of the humidifier. In this connection, means are provided toprevent recirculation of the air already humidified.

It would also be possible to mount the unit for use as a roomhumidifier.

In addition, the circulating fan and its drive motor are mounted in aunique way which protects the motor from the effects of moisture andheat.

Further novel features and advantages will becom apparent as thedescription progresses.

The accompanying drawings illustrate the best mode presentlycontemplated by the inventor for carrying out the invention.

In the drawings:

FIGURE 1 is an exploded perspective View of a casing constructed inaccordance with the invention, and showing the top cover and gas-liquidcontact unit raised from their normal positions;

FIG. 2 is a generally vertical section through the casing; and

FIG. 3 is a top plan view of the humidifier with parts broken away andin section.

As shown in the drawings, the casing of the invention has the usual top,floor, side walls and end walls and comprises, generally, a bottomsupport section 1 and a top shroud section 2 which are adapted toabuttingly engage each other along a horizontal joint 3. 'These shellsectrons may be secured together by any suitable means. For example,joint 3 may be provided with several interrelated ridges or flanges 4,and a horseshoe-shaped holding clip 5 of nylon strip or the like may beslipped on or off them as desired.

Sections 1 and 2 are preferably molded from a thermosetting plastic.High strength and heat and water resistance are desirablecharactenis-tics obtained with this material, which may also provide anadditional safety factor by having a dry dielectric strength of about250 volts/ mil.

The humidifier assembly is shown as having a major chamber portion 6with greater width than depth. The long rear wall is adapted forsecurement to a furnace or other suitable fiat surface. The long frontwall opposite the furnace connection portion is provided with an openingwhich connects to a small chamber 7 adapted to receive a fan motor d andany other suitable controls. Mot-or 8 may be automatically actuated by ahumidistat or other controlling apparatus.

FIGURE 1 shows the casing separated, revealing that many of the majorcomponents of the humidifier are supported by bottom casing section 1.

It has been found that motor 8 and other controls will have an increasedlife if they are removed from a moist atmosphere. They therefore mustnot be within the air air. This problem is solved by mounting motor 8and the controls to the front face of a hat vertical panel 9 by means ofbolts 10 or the like.

Panel 9 is imperforate and is preferably made of a material similar tosections 1 and 2. The side edges of the partition panel are adapted tofit within coextensive grooves or slots 11 formed along thecorresponding edges of the opening in the front wall of chamber 6 formedby sections 1 and 2. When top section 2 is removed, panel 9 may be slidinto or out of the U-shaped lower slot portion in the'bottom casingsection. Assembly and servicing of motor 8 and its controls is therebyfacilitated. 7

When section 2 is replaced, chamber 7 is substantially sealed from thelarge humidifying chamber 6 by the interior partition 9 which forms aninner vertical wall of each chamber and which protects the working partsin chamber 7 from corrosion caused by excess moisture. In addition,ventilation of chamber 7 with the dry air existing in the building isprovided by a series of vents 12 formed into an outside wall of thechamber 7.

Since motor 8 may be somewhat heavy, relative to the gauge of panel 9, asupplemental resilientsupport for the motor is provided. Such a supportmay comprise that shown in FIG. 2, wherein the floor of casing 1 atchamber 7 extends upwardly to create an integral projection 13 having .athreaded vertical opening therein. A postlike stud or bolt 14 isthreaded into the opening and extends upwardly from projection 13 wherea resilient cap 15 on the upper end thereof supports motor 8.

Bolt 14 has a notched lower end to receive a screw driver for adjustingthe same vertically toallow for variations in motor size. The bolt 14resiliently restrains motor 3 from vibration due to any accentricity ofits operating fan 17. As shown, thisshroud forms part of an integralinsert member, indicated generally at 20, and comprises 'the front wall21 thereof which extends between the casing side walls. A fan receivingopening 22 in wall 21 is of a minimum size commensurate with thediametrical extent of the fan.

Extending rearwardly from each side edge of wall 21 is an integral wallwhich comprises a pair of wall portions :23 and 24 which are offset by atransverse shoulder 25.

The construction is such that the opposed wall portions 23 are spacedcloser together than the opposed wall portions 24. In addition, aninwardly extending vertical rib 26 is disposed on each wall portion 24and spaced fromthe rear edge thereof and generally parallel to shoulder25, to provide an end lip or baffle portion 27, described more fullyhereinafter. The rear end of insert 28 is generally open.

The described construction provides a channel formed by 'walls 24,shoulders 25 and ribs 26 to receive a vertical gas-liquid contact unit28 which is on the opposite side of fan 17 from panel 9 and generallyparallel to the latter. Unit 28 forms an outer vertical wall of chamber.6. With metal channels, the tenacious scale from hard waters would lockthe evaporative unit to the channels. However, scale will not form soreadily on the smooth substantially eliminated. V Insert 20 provides anintegral fan shroud and channel support structure for the evaporativeelement 28. This unitary element is anchored to the floor of chamber 6,

such as by a slot or groove 29 which is molded into the floor and whichconforms to the bottom edge contour of the insert. Complete andpermanent securement may be assured by utilizing an epoxy resin or othersuitable cementing material at the groove.

In addition, the top edge of insert 20 is adapted to fit within a slotor groove 30 molded into the top wall of upper half 2 'of the casing. Topermit removal of the casing top, this upper joint is merely amechanical fit,

'no cementing materials being employed.

As best seen in FIG. 3, insert 20 is disposed so that ribs 26 are spacedinwardly from the rear edge of bottom member 1, with baflle elements 27extending just to the said rear edge;

When the unit iscompletely assembled, it can be seen that insert 20provides the necessary separating'elements 4 parallel to the upward flowof air within the plen chamber of the furnace into which they areadapted to extend. This permits minimum mechanical resistance to themoving air.

Tests have shown that, with an air velocity of 230 ft./min. in the.plenum chamber and an'air volume of 200 cubic ft./min. passing throughthe humidifier, the rate of evaporation increased 44% when a baflie 27of inch outward extent was utilized, compared to a structure wherein nobaffie was used.

The gas-liquid contact unit 28 is adapted to receive water which Wetsall of the surfaces thereof whereby the airpassing therethrough isproperly humidified. For this purpose, a gravity water distributionsystem may be used. .Such a system is shown in US. Patent No. 2,637,540wherein a tubular member having a plurality'of spaced holes along thebottom thereof is disposed above the upper edge of the contact unit.

An'improv ed distributor is shown in US. Patent No. 2,947,452, which isassigned to the same assignee as the present invention. In that patent,a separate distributor .trough. is provided with openings having a waterin- .soluble hydrophilic composition disposed closely adjacent thereto.The coating promotes a steady and uni- .form flow of water from thetrough through the openings,

.and utilizes a wicking action to produce the desired result. a

A similar principle is used in the present structure,

' wherein a water trough 31 is molded into top section 2 plasticchannels, and the problem of locking is thereby as an integral partthereof. Trough 31 is disposed adjacent the rear portion of section 2and extends downwardly into chamber 6 to directly above unit 28.

As in Patent No. 2,947,452, a plurality of spaced discharge apertures 32are molded in trough 31 and have for air flow into and out ofhumidifying chamber 6. This 1 is due to the fact that walls 23 and 24are spaced a substantial distance from the side walls of the chambertothereby provide air discharge openings 19. The air'inlet opening 18 isthe open rear side of the insert.

When used with a furnace or air duct, air to be drawn through theair-liquidcontact unit 28 enters chamber 6 as shown by the arrows inFIG. 3, and is discharged in the opposite but a parallel direction.Other uses for the humidifier might require a change in direction ofdischarge.

It is important to minimize any recirculation 'of humidified air withdry air caused by intermingling of the two types of air adjacentopenings 18 and 19. This shortcircuiting of the air has been found tolimit the rate of evaporation of moisture. By providing bafiles 27 whichextend outwardly beyond ribs 26 this undesirable phenomenon issubstantially reduced and humidified air is directed away from theintake.

a The casing extensionbaifles 27 are disposed between the intake anddischarge flows and are disposed parallel to both. In addition, beingvertical in extent, they are V-notch weirs formed by cylindrical risers33. A ring or snout 34 surrounds each aperture 32 on the underside ofthe trough to facilitate'dripping of water directly down from the'aperture. of unit 28.

Since trough 31 is integral with top section 2, it cannot rattle or getout of place; nor can it permit air to by-pass its perimeter. In.addition, it is automatically aligned with the vertical channel guidesfor unit 28, and

Snout 34 normally touches the top thus with the unit itself. The factthat the trough is open to the outside of'the top casing makes it easilyaccessible for cleaning, and observation of its proper functioning isfacilitated. For example, the levelness of the distributor can be easilychecked by observing the surface of waterin the trough. If .the troughgets too limed up for proper functioning, it is easily replacedwithout'dis- 'turbing the rest of the apparatus by replacing top member2.

It is important to prevent any water in chamber 6 from 'being blownthrough discharge openings 19 into the furnace plenum chamber. If fan 17is too close to unit 28, entrained water will be sucked out ofthe unitand blown through openings 19. This problem can be eliminated byproperly spacing the fan from the inner wall of the gas-liquid contactunit. With the present assembly it has been found that a spacing of notless than about /2 inchwill avoid the difliculty.

There is normally a space of about inch between snouts' 34 and the topof unit 28. Since water collects on snouts 34 in droplet form, fan 17may tend to suck some "of the droplets through this space and hence toopenings 19; The present construction eliminates this problem byproviding a horizontal bafiieor skirt 35 which is ent construction thedownward extent to the lower edge of. the skirt is about inch, so thatthe skirt overlaps and contacts the inner face of unit 28.

Skirt 35 serves to stop removal of the water droplets by the fan, andinstead direct them down onto the humiditying unit. In addition, theskirt compels air to move through the contact unit, since it cannotbypass above the unit.

Water which is not collected by the dry air passing through thehumidifier will, in time, tend to flow down unit 28. In this connection,it is necessary to provide means for removal of this excess water. Thestructure of the invention provides an improved drain technique. As bestseen in FIG. 2, gas-liquid contact unit 28 rests directly on the floorof chamber 6. The entire floor area of the chamber bounded by raisedgroove 29 and by an upwardly curved bottom rear edge or lip 36 ofsection 1, serves as a sump into which the water drains. Any waterrunning down unit 28 or its supporting channels will be collected inthis large sump area. This will prevent water from seeping, often by aprocess of scale deposition, to undesired areas.

' If desired, a plurality of ribs 37 may be molded in fanlike arrayacross the bottom of the sump area to beneath unit 28 to help direct thewater to a depressed floor section 38 at the forward part of the sumpand close to fan wall 21. A drain opening 39 in section 33 removes waterfrom the humidifier for recirculation of other disposal.

The entire assembly may be secured to the wall 40 of a furnace plenumchamber, as by a flange 41 which extends around the rearedge portion ofthe casing. At the top of the casing, this flange forms a part of therear wall of trough 31.

It has been found that the entire humidifier runs at a substantiallylower noise level than those of prior construction. It is believed thatthe use of an all-plastic casing, which has a high coefficient of soundabsorption, greatly assists in this regard. The noise level has beenfound to be approximately 25% less than that of prior metal units.Locating the motor in an isolating chamber of this plastic material andutilization of the plastic fan shroud also have an important bearing onthe quiet operation obtained.

Various modes of carrying out the invention are contemplated as beingwithin the scope of the following claims particularly pointing out anddistinctly claiming the subject matter which is regarded as theinvention.

I claim:

1. In a humidifying apparatus,

(a) top and bottom casing sections,

(b) means to separably join said sections at a generally horizontalparting line to form a humidifier casing having a top, a floor, sidewalls, and end walls,

(c) one of said end walls having an opening for passage of gastherethrough,

(d) a gas flow fan disposed within said casing inwardly of said end wallopening,

(e) means to rotate said fan,

(f) an integral member vertically disposed within said casing andcomprising:

(1) an inner vertical shroud wall extending between the casing sidewalls and with said shroud wall having a central opening within whichsaid fan is disposed,

(2) a side wall separate from the casing side walls and extending fromeach vertical edge of said shroud wall to adjacent but spaced slightlyinwardly of said end wall opening,

(3) each of said last-named side walls having an offset shouldertherein,

(4) and a rib disposed adjacentthe outer end of each of said last-namedside walls and extending inwardly and generally parallel to said offsetshoulders;

(g) a vertical gas-liquid contact unit supported by said floor andsupportingly disposed between the said offset shoulders and the saidribs,

(h) a groove disposed in said floor and receiving the bottom edge ofsaid integral member,

(i) a groove disposed in said top and receiving the 6. top edge of saidintegral member when said top and bottom casing sections are joined,

(j) and means disposed above said integral member to supply liquid tothe upper portion of said unit.

2. The combination of claim 1 in which:

(a) the side walls of said integral member are spaced inwardly from theside walls of said casing to separate said end wall opening into gasinlet and discharge passages,

(b) and each said rib on said integral member being disposed inwardly ofthe outer vertical edge portion of the respective side wall thereof, sothat each said vertical edge portion forms a bafiie parallel to andseparating the gas inlet and discharge fiows at said end wall opening.

3. In a humidifying apparatus:

(a) a pair of casing sections,

(b) means to separably join said sections to form a casinghaving a top,a floor, side walls and end walls,

(c) one of said end walls having an opening for passage of gastherethrough,

(d) a gas flow fan disposed within said casing inwardly of said end wallopening,

(e) an integral member vertically disposed within said casing andcomprising:

(1) an inner vertical shroud Wall extending between the casing sidewalls and with said shroud wall having a central opening within whichsaid fan is disposed,

(2) and a side wall separate from the casing side walls and extendingfrom each vertical edge of said shroud wall to adjacent but spacedslightly inwardly of said end wall opening, the side walls of saidintegral member being spaced from the side walls of said casing to formair passages therebetween.

(f) a vertical gasdiquid contact unit supported by said floor andextending between the side walls of said integral member,

(g) means on said integral member to support the vertical edge portionsof said unit,

(b) means disposed above said integral member to supply liquid to theupper portion of said unit, (i) and a sump disposed beneath said unit toreceive excess liquid therefrom, the boundaries of said sump comprising:

(1) a raised groove disposed in said casing floor and receiving thebottom edges of the shroud wall and side walls of said vertical member,

(2) an upwardly curved lip extending along the outer edge of said casingfloor adjacent said end wall opening,

(3) and the said floor.

4. The combination of claim 3 in which the liquid supply meanscomprises:

(a) a distributor trough molded integrally with the top casing sectionand disposed above and in aligned relationship with the said contactunit when the top and bottom casing sections are assembled,

(b) and a transverse skirt integral with and extending downwardly fromthe inner wall of the trough and terminating at a horizontal edgedisposed below the top of the contact unit so that liquid between thetrough and the contact unit will be protected from air flow.

5. In a humidifying apparatus:

(a) top and bottom casing sections of molded synthetic plastic material,

(b) means to separably join said sections at a generally horizontalparting line to form a humidifier casing,

(c) coextensive vertical inner grooves disposed in opposite side wallsof said sections,

(d) a fiat imperforate vertical panel of molded plastic material havingits side edges disposed in said grooves,

*(f) a motor disposed within said first chamber and secured to saidpanel,

(g) a fan disposed in said second chamber and connected to said motorthrough said panel for rotation by the motor,

(h) and a vertical gas-liquid contact unit disposed on the opposite sideof said fan from said panel and generally parallel to the latter,

(i) said contact unit forming an outer vertical wall of said secondchamber so that gas will be drawn through the unitwhen said motorrotates said fan,

(j) outlet means in said casing for discharge of humidified air, I

'(k) said panel, together with said motor and fan, being freelyslideable vertically out of the grooves in said lower casing sectionwhen said upper casing section is removed,

(1) a vertical post disposed in said first chamber and centrally beneathsaid motor and secured to the floor of said bottom casing section,

(m) a resilient vibration absorbing member disposed on the upper end ofsaid post and engaging said motor,

(n) and means for adjusting 8 i I s'ai'd p ost vertically's'o that itwill support said motor. I

' References Cited by theExaininer UNITED STATES PATENTS 2,189,021 72/40 Schury 261-91 XR 2,561,592 7/51 Palmer 261-24 2,628,083 2/53 7Rense 261-28 X 2,637,540 5/53 Rowe 261-94 2,668,038 2/54 Dry' 261-119 XR2,705,623 4/55 Glassenhart et a1. a 26 1-29 1 2,751,760 6/56 Williams62-429 XR 2,766,027 10/56 Herr 26 1-91 2,838,130 6/58 Lemmon 261-26 X2,849,020 8/58 Goff. 2,860,228 11/58 Boyle et al. I 1 2,947,452 V 8/60Frohmader et a1. j 222-478 XR 2,984,464 5/61" ,Herr 261-91 XR 2,998,7149/61 Bonzer. r 3,023,837 3/62 Weills. a r 3,131,236 4/64 Beehler et a1.261-28 HARRY VB. THORNTON, Primary Examiner. HERBERT -L. MARTIN,Examiner,

1.IN A HUMIDIFYING APPARATUS, (A) TOP AND BOTTOM CASING SECTIONS, (B)MEANS TO SEPARABLY JOIN SAID SECTIONS AT A GENERALLY HORIZONTAL PARTINGLINE TO FORM A HUMIDIFIER CASING HAVING A TOP, A FLOOR, SIDE WALLS, ANDEND WALLS, (C) ONE OF SAID END WALLS HAVING AN OPENING FOR PASSAGE OFGAS THERETHROUGH, (D) A GAS FLOW FAN DISPOSED WITHIN SAID INWARDLY OFSAID END WALL OPENING, (E) MEANS TO ROTATE SAID FAN, (F) AN INTEGRALMEMBER VERTICALLY DISPOSED WITHIN SAID CASING AND COMPRISING; (1) ANINNER VERTICAL SHROUD WALL EXTENDING BETWEEN THE CASING SIDE WALLS ANDWITH SAID SHROUD WALL HAVING A CENTRAL OPENING WITHIN WHICH SAID FAN ISDISPOSED, (2) A SIDE WALL SEPARATE FROM THE CASING SIDE WALLS ANDEXTENDING FROM EACH VERTICAL EDGE OF SAID SHROUD WALL TO ADJACENT BUTSPACED SLIGHTLY INWARDLY OF SAID END WALL OPENING, (3) EACH OF SAIDLAST-NAMED SIDE WALLS HAVING AN OFFSET SHOULDER THEREIN, (4) AND A RIBDISPOSED ADJACENT THE OUTER END OF EACH OF SAID LAST-NAMED SIDE WALLSAND EXTENDING INWARDLY AND GENERALLY PARALLEL TO SAID OFFSET SHOUDLERS;(G) A VERTICAL GAS-LIQUID CONTACT UNIT SUPPORTED BY SAID FLOOR ANDSUPPORTINGLY DISPOSED BETEEN THE SAID OFFSET SHOULDERS AND THE SAIDRIBS, (H) A GROOVE DISPOSED IN SAID FLOOR AND RECEIVING THE BOTTOM EDGEOF SAID INTEGRAL MEMBER, (I) A GROOVE DISPOSED IN SAID TOP AND RECEIVINGTHE TOP EDGE OF SAID INTEGRAL MEMBER WHEN SAID TOP AND BOTTOM CASINGSECTIONS ARE JOINED, (J) AND MEANS DISPOSED ABOVE SAID INTEGRAL MEMBERTO SUPPLY LIQUID TO THE UPPER PORTION OF SAID UNIT.